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Wiring Harness Inspection

10 points

Overview

This assignment guides students in visually inspecting a wiring harness to identify common defects such as damaged wires, poor connectors, or insulation issues. Students will document their findings with a photo and a brief report, developing essential skills in harness condition assessment for safety and reliability.

Resources

FAA AC 43.13-1B - Chapter 11, Sections 8-12

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Assignment

Document Preparation

Copy this document to your own Coda E-portfolio page using the “Copy doc” button in the top right.

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Be sure to add it to the AT 209 section.

If you wish, you can hide this worksheet after completion by selecting “Hide page” from the page’s menu bar.

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Photograph Wiring Harness

Identify a wiring harness from an approved piece of equipment, such as a vehicle, plane, or training/simulator station.

Take a well-lit photo of the wiring harness.

Be sure to capture all ends of the wiring harness (it may run point to point or it may include several breakouts).

Upload your photo(s) to the

Photos⁠

section below.

Report of Findings

Conduct a brief visual inspection of the harness, focusing on the following:

Condition of the wires (check for cuts, cracks, abrasions, fraying, or exposed conductors)

Integrity of insulation and coverings (look for missing tape, damaged conduit, or heat damage).

Condition of connectors (check for corrosion, broken clips, loose or bent pins).

Signs of overheating (burn marks, melted insulation).

Routing and securing (whether the harness is adequately supported, tied down, and clear of moving parts or sharp edges).

Write a short

Inspection Report⁠

(½ to 1 page maximum) that includes:

The photo of the harness.

A summary of your observations. Be sure that your observations use language represented in

FAA AC 43.13-1B - Chapter 11, Sections 8-12⁠

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Any defects or concerns you noticed.

A recommendation (e.g., “harness is acceptable for use,” “minor repair needed,” or “should be replaced”).

Photos

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Inspection Report

The image above is the wiring harness for the fuse box in my friend’s GMC Yukon. The condition of the wires is very good given how old the vehicle is. There are no visible cuts, cracks, abrasions, or frayed conductors. There is also no exposed copper or damaged wire stands. The insulation appears to be in good condition and continuous along the entire visible section that is uncovered. The electrical tape, while slightly worn and dusty, is intact and good condition. There are no signs of melted insulation or heat damage. The primary connector housing is seated properly and undamaged, the red locking tab is correctly engaged, and there is no corrosion, no bent pins, or broken clips visible externally. There are also no signs of overheating or melted plastic on the harness or connectors. The harness routing is proper and secure. It is clear of sharp edges and moving components meaning it has no risk of damage during operation. There is some slight slack in the wire but it is within acceptable limits for vibration limits. The only concerns/defects present is the wear on the electrical tape around the beginning of the uncovered wires. This is typical for where it is in the engine bay but it might be beneficial to replace it eventually to ensure no possible chance of damage to the uncovered section. The wire harness is acceptable for continued use. If the harness shows any further degradation or exposure to the elements it would be beneficial to re-wrap to maintain insulation intengrity.